Orthotic device with snap fit cuff and latch mechanism

ABSTRACT

An orthotic device including a frame assembly and a support structure. The frame assembly includes at least one frame having a first frame opening and a second frame opening. The support structure assembly includes at least one support structure supported by the at least one frame. The at least one support structure includes a mounting portion; a slide engagement member supported by the mounting portion configured to engage the first frame opening; and, at least one snap engagement member supported by the mounting portion configured to engage the second frame opening. The slide engagement member and the at least one snap engagement member are integrally formed with the mounting portion. In another embodiment the orthotic device includes a latch mechanism including a lever assembly, a draw bar, a chafe, a catch, and a first snap fit ledge.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefits of U.S. application Ser. No.15/097,458, filed Aug. 6, 2019, entitled ORTHOTIC DEVICE WITH SNAP FITCUFF AND LATCH MECHANISM, which claims the benefit of U.S. ProvisionalApplication Ser. No. 62/149,029, filed on Apr. 17, 2015, entitledORTHOTIC DEVICE WITH SNAP FIT CUFF AND LATCH MECHANISM. The entirecontents of Ser. Nos. 15/097,458 and 62/149,029 are hereby incorporatedherein by reference thereto.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates generally to the field of orthopedicsupports and braces, and specifically ease of use and inventiveimprovements to manufacturability.

2. Description of the Related Art

Orthopedic braces and supports are medical devices, and are mainlydesigned to be functional in nature. Over and above functionality,braces and supports are in a special category since they are worn on thebody and their success is heavily dependent on easy and intuitivepatient interaction. The issue of patient compliance is high on aninventor's list of design criteria since the brace does no good if thepatient chooses not to wear it. Many factors contribute to a patient'schoice whether to continue wearing a brace or support. Fit,functionality, and comfort are top priorities, but there is also ease ofuse and other human factors that have the potential to either decidesuccess, or doom a brace/support to the patient's closet.

In addition to these considerations, there is the desire to improvemanufacturability of the product, which will limit defects, improvequality, and therefore also improve the patient's experience.

Prior art includes many methods to secure the brace/support to theanatomy. The most commonly practiced method uses hook & loop strapswhich are ubiquitous, but do have their issues. For example, the elderlyor less dexterous have complaints regarding peeling the straps apart toexit (“doff”) the brace, and further complaints about the strapssticking to each other, clothing, furniture, etc. Elderly or lessdexterous patients also sometimes have a difficult time exerting enoughforce to pull the straps tight and fasten them when entering (“donning”)the brace/support. Some of the prior art includes different forms ofmechanical advantage to help don the brace, coupled with means to doffthe brace without peeling the straps each time.

There has been a partial response to this problem in current art, asseen in U.S. Pat. No. 8,257,293, issued to Ingimundarson et al. entitledKNEE BRACE AND METHOD FOR SECURING THE SAME. The '293 patent discloses abuckle assembly that can also be described as a draw latch mechanism.

SUMMARY OF THE INVENTION

In a broad aspect, the present invention is a latch mechanism includinga lever assembly, a draw bar, a chafe, a catch, and a first snap fitlatch. The lever assembly includes a lever; a lever axle depending fromthe lever at a first end thereof, for securing the lever to a supportstructure of the orthotic device; and a first snap fit hook projectingfrom the lever. The drawbar is pivotably attached to the lever. Thechafe is attached to the drawbar. The catch extends from the supportstructure to receive the lever axle. The first snap fit ledge dependsfrom the support structure to engage and hold the first snap fit hook.The catch is configured to stand substantially above a nominal height ofthe support structure such that the lever axle is easily received by thecatch for fastening by the user.

In another broad aspect the invention is embodied as an orthotic deviceincluding a frame assembly and a support structure. The frame assemblyincludes at least one frame having a first frame opening and a secondframe opening. The support structure assembly includes at least onesupport structure supported by the at least one frame. The at least onesupport structure includes a mounting portion; a slight engagementmember supported by the mounting portion configured to engage the firstframe opening; and, at least one snap engagement member supported by themounting portion configured to engage the second frame opening. The saidslide engagement member and the at least one snap engagement member areintegrally formed with the mounting portion.

In one preferred embodiment, the orthotic device is shown as a kneebrace with at least one latch mechanism attached to a pivotable D-ringchafe. The chafe has a slot that the strap is looped through.

The latch mechanism preferably includes a draw latch. The latchmechanism tightens and secures the straps around the user's anatomy, andalso gives the user a mechanical advantage over just manually pullingthe strap tight. It also allows for doffing/donning the brace withoutpeeling the hook/loop on the straps. The latch mechanism un-clips andallows the strap to be loosened enough to remove the end of the strap,then remove the brace.

When the brace is ready to be donned again, the original strap lengthsettings are saved, so it is very quick, easy, and convenient for theuser to don the brace as compared to just a hook and loop strap alone.

The invention disclosed in U.S. Pat. No. 8,257,293 is a draw latchassembly, but it lacks ease of use when fastening it to the brace. Thelatch disclosed in that '293 patent includes a mushroom-shaped head thatslides into a “keyhole” on the brace frame. The problem with such adesign is that the user must push the head against the anatomy andsoftgood pad liner to get it engaged in the keyhole.

On the other hand, the present invention solves this issue by includinga catch protruding from a nominal height of the main surface of thebrace. The latch lever has an axle that easily slides under the catch,allowing for quick, easy, and convenient use by less dextrous or elderlypatients. These types of patients are the main demographic for bracessuch as this, and user friendly features will aid in patient complianceand therefore positive outcomes in treatment.

Bulk or high-profile design is not an issue with this embodiment, sincethe catch is preferably made no taller than the main latch mechanismitself.

This embodiment includes snap-fits which are released by simply pullingup on the lever component, however there are many other ways toaccomplish the fastening and release. Side push-buttons, toppush-buttons are alternate embodiments. These, in turn, can be designedto have a single-push or a double-push configuration. The double sidepush for example, would require a “pinch” force from the user, so itwould not be ideal for the elderly or patients with less hand strength.Still other means can include pivoting or rotating actions to release.Each of the above can be augmented with an additional spring-loadedfeature to allow release of the mechanism.

In another broad aspect, the draw latch preferably has a pivotable chafeattached at one end where the strap is looped through a slot on thechafe. Prior art shows the entire latch mechanism pivoting. The presentinvention simply pivots the chafe itself at the end of the mechanism.This novel approach reduces the number of moving parts (or at leastparts moving in multiple directions) and places the pivoting motionwhere it is most functional—at the edge of the frame where the strapmeets the anatomy.

In another embodiment, the orthotic device includes fastening featuresbuilt in or integrated directly into the frame components. Contrast thisto prior art which requires the use of separate fastening componentssuch as rivets or screws. This allows for quick, easy manufacturing ofthe product at a lower cost due to fasteners not being needed. It alsoresults in a sleeker, better-looking product that will increase patientcompliance.

The present embodiment includes a slide engagement member on the cuffthat is passed through and slid across a first opening on the frame.Then a snap engagement member on the cuff is snapped through a secondopening on the frame to complete the assembly. Compare this topurchasing separate rivet or screw components, then positioning the cuffand frame together, passing at least 2 rivets or screws through holes inthe cuff and frame, placing the entire assembly in a pneumatic rivetingmachine, and finally fastening the rivets.

Rather than a “slide-&-snap,” many other means for fastening the bracetogether can be imagined, such as a keyhole coupled with a snap fit.Another means could be a double keyhole that includes two “mushroomhead” protrusions that pass through 2 keyhole openings in the frame. Thekeyholes are comprised of one large and one small diameter hole thatallow the protrusions to pass through freely, then lock down as the cuffis slid through and snapped into the smaller of the two holes in thekeyhole feature. Of course, all the embodiment features above can beinterchanged between cuff and frame.

Other objects, advantages, and novel features will become apparent fromthe following detailed description of the invention when considered inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of the orthotic device of the presentinvention.

FIG. 2 is a bottom perspective view of the orthotic device.

FIG. 3 is a perspective view of the orthotic device, with the latchmechanism open.

FIG. 3 is a perspective view of the orthotic device, with the latchmechanism open.

FIG. 4 is a perspective view of the orthotic device, with the lever axleattaching to the catch.

FIG. 5 is a perspective view of the orthotic device, with the levershown moving toward closure.

FIG. 6 is a perspective view of the orthotic device, with the latchmechanism shown closed.

FIG. 7 is a view showing along line 7-7 of FIG. 1.

FIG. 8 is an enlarged plan view of the latch mechanism.

FIG. 9 shows the chafe pivoted to a different position.

FIG. 10 is an exploded perspective view of the frame and the supportstructure.

FIG. 11 is a perspective view of the frame attached to the supportstructure.

FIG. 12 is a perspective view of a portion of the orthotic device withan alternative lever utilizing a top push button.

FIG. 13 is a perspective view of a portion of the orthotic device withan alternative lever utilizing a single side push button.

FIG. 14 is a perspective view of a portion of the orthotic device withan alternative lever utilizing a double-push configuration.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings and the characters of reference markedthereon, FIGS. 1 and 2 illustrate a preferred embodiment of the presentinvention, designated generally as 10. The orthotic device 10 includes aframe assembly, designated generally as 12; and, a support structureassembly, designated generally as 14.

In this preferred embodiment the frame assembly 12 includes an upperframe 16 and a lower frame 18. The upper frame 16 and the lower frame 18are connected by a hinge center assembly 20. The hinge center assemblyincludes hinge center plates 22, fasteners 24, and a condyle cup 26. Italso includes an angulation hinge 28 for providing correction to theknee. The angulation hinge can be adjusted to angle the brace to fit theanatomy more closely. The angulation hinge can also be adjusted to allowthe brace to provide an unloading force to the knee joint to helprelieve knee pain. The upper frame 18 has a first frame opening 30 and asecond frame opening 32.

The lower frame 18 is constructed in a similar manner as the upperframe. The upper frame and lower frame are preferably formed of metal.Alternatively, they can be formed of resilient plastic.

The support structure assembly 14 is supported by the frame assembly 12.The support structure assembly 14 includes an upper support structure 34and a lower support structure 36. These support structures are alsoknown in this field as “cuffs.” The upper support structure 34 includesa mounting portion 38, a slide engagement member 40 supported by themounting portion 38 and configured to engage the first frame opening 30,and at least one snap engagement member 42 supported by the mountingportion 38 and configured to engage the second frame opening 32. Theslide engagement member 40 and the snap engagement member 42 areintegrally formed with the mounting portion 38.

The upper support structure 34 and the lower support structure 36 arepreferably formed of resilient plastic.

The present invention improves the manufacturability of the supportstructures and the frame assembly of the orthotic device. The mostcommonly heretofore practiced method to assemble the product together isthe use of separate fastener parts, such as rivets or screws. Thepresent invention eliminates these extra parts in favor of designing thefastening features directly into the parts being joined. Thisintegration of components improves manufacturability, lowers cost, andresults in a better looking product with no fasteners showing on theoutside for the user to see, making the product more desirable to wear,thus increasing patient compliance.

The orthotic device 10 includes latch mechanisms, designated generallyas 44, for securing straps 45 to respective support structures.Referring to FIGS. 3-6, a latch mechanism 44 is illustrated inoperation. Each latch mechanism 44 includes a lever assembly, designatedgenerally as 46. Each lever assembly 46 includes a lever 48, a leveraxle 50 depending from the lever 48 at a first end thereof, for securingthe lever 48 to a support structure (e.g. upper support structure 34) ofthe orthotic device 10; and, a first snap fit hook 52 projecting fromthe lever 48.

A draw bar 54 is pivotably attached to the lever 48. A chafe 56 isattached to the draw bar 54. A catch 58 extends from the supportstructure 34 to receive the lever axle 50. A first snap fit ledge 60depends from the support structure 34 to engage and hold the first snapfit hook 52. The catch 58 is configured to stand substantially above anominal height of the support structure 34 such that the lever axle 50is easily received by the catch 58 for fastening by the user. Thenominal height is the height of the outside surface of support structure34 at the region where the catch 58 extends from the support structure34. Thus, the term “substantially above” refers to a height above thediameter/thickness of the lever axle 50.

The chafe 56 is preferably a D-ring chafe. The lever assembly 46preferably includes a second snap fit hook 62 spaced from the first snapfit hook 52 projecting from the lever 48.

The straps 45 may be of a conventional type typically used for braces,typically formed of woven nylon.

Referring now to FIG. 7, the association of the first snap fit hook 52,the second snap fit hook 62, and the upper support 34 are shown clearlywhen the latch mechanism is in a closed position. This figure also showsthe relationship of the lever axle 50 and the catch 58. It also showsthe engagement of the draw bar 54 and the chafe 56.

FIGS. 8-9 show the pivoting motion of the chafe 56. The draw bar 54includes a major axis 57 along the length thereof and a minor axis 59along a width thereof. The D-ring chafe 56 is pivotably attached to thedraw bar 54 around a pivot axis 61 (shown in FIG. 7) substantiallyperpendicular to the major axis 57 and the minor axis 59.

Referring now to FIGS. 10-11 show the first frame opening 30 engagingthe slide engagement member 40 and the second frame opening 32 engagingthe snap engagement member 42. The first frame opening 30 is slid overthe slide engagement member 40 (as shown by Step A) then the secondframe opening 32 is rotated down to snap over the snap engagement member42 (as shown by Step B). This secures the upper frame 16 to the uppersupport structure 34. This obviates the use of external or separatefastening parts.

Referring now to FIG. 12, an alternate embodiment to lever 48 is shown.This embodiment utilizes a top push button 70. Pushing the top pushbutton 70 causes snap fit hook 52 to engage or disengage from snap fitledge 60.

Similarly in FIG. 13, another alternate embodiment to lever 48 is shown.This embodiment comprises a single side push button 75. Pushing the sidebutton 75 causes snap fit hook 52 to engage or disengage from snap fitledge 60.

Similarly in FIG. 14, another alternate embodiment to lever 48 is shown.This embodiment comprises a double-push or “pinch” configuration 80.Pinching the double side buttons 80 causes snap fit hook 52 to engage ordisengage from snap fit ledge 60.

These and other alternate embodiments to lever 48 allow greater ease ofuse and security by separating the direction of initiating the releasefrom the release motion itself. For example, in FIG. 13, the directionof initiating the release when pushing button 75 is parallel to lever48, while the release motion itself is a rotation of lever 48.Separating these two motions ultimately allows a strong and robustrelease force that can be started by a relatively small initiatingforce.

Although the invention has been described with respect to a specificembodiment it is understood that is within the scope of the inventionthat, for example, the orthotic device may include only an upper frameor a lower frame. Also, for example, although the support structureassembly has been described as having an upper support structure and alower support structure, it is understood that it is within the purviewof this invention to have a support structure assembly which includesonly an upper support structure or a lower support structure. Althoughthe invention has been described reference to a first and a second snapfit hook, it is understood that in some embodiments only a single snapfit hook may be used. Furthermore, additional snap fit hooks may beused. Although the rate has been shown on the lateral side of the leg itis understood that it can alternately be applied on the medial side. Theinventive concepts described herein have been discussed relative to theapplication on a knee; however, it is within the purview of thisinvention to have an orthotic device that can be used on other portionsof the anatomy. These other portions of the anatomy may include, forexample, hands, wrists, shoulders, arms, ankles, hips, legs and spines.

Other embodiments and configurations may be devised without departingfrom the spirit of the invention and the scope of the appended claims.

1. An orthotic device, comprising: a latch mechanism, said latchmechanism, including: a) a lever assembly, comprising: i) a lever; ii) alever axle depending from said lever at a first end thereof, forsecuring the lever to a support structure of the orthotic device; and,iii) a first snap fit hook projecting from said lever; b) a draw barpivotably attached to said lever; c) a chafe attached to said draw bar;d) a catch extending from the support structure to receive said leveraxle; and, e) a first snap fit ledge depending from the supportstructure to engage and hold said first snap fit hook; wherein saidcatch is configured to stand substantially above a nominal height of thesupport structure such that the lever axle is easily received by saidcatch for fastening by the user.
 2. The orthotic device of claim 1,wherein said chafe comprises a D-ring chafe pivotably attached to saiddraw bar.
 3. The orthotic device of claim 1, wherein said lever assemblycomprises a second snap fit hook spaced from said first snap fit hookprojecting from said lever.
 4. The orthotic device of claim 1, furtherincluding a strap attachable to said chafe.
 5. The orthotic device ofclaim 1, wherein said lever and said snap fit hook are integral.
 6. Theorthotic device of claim 1, wherein said snap fit hook is engaged orreleased from said snap fit ledge by pulling up on said lever.
 7. Theorthotic device of claim 1, wherein said lever comprises a push buttonthat functions to engage or release said snap fit hook from said snapfit ledge.
 8. The orthotic device of claim 1, wherein said levercomprises a pinch configuration that functions to engage or release saidsnap fit hook from said snap fit ledge.
 9. An orthotic device,comprising: a) a frame assembly comprising at least one frame having afirst frame opening and a second frame opening; b) a support structureassembly comprising at least one support structure supported by the atleast one frame, said at least one support structure including: i) amounting portion; ii) a slide engagement member supported by saidmounting portion configured to engage said first frame opening; and,iii) at least one snap engagement member supported by said mountingportion configured to engage said second frame opening, wherein saidslide engagement member and said at least one snap engagement member areintegrally formed with said mounting portion.
 10. The orthotic device ofclaim 9, further including a latch mechanism for securing a strap to thesupport structure.
 11. The orthotic device of claim 10, wherein saidlatch mechanism comprises: a) a lever assembly, comprising: i) a lever;ii) a lever axle depending from said lever at a first end thereof, forsecuring the lever to said support structure of the orthotic device;and, iii) a first snap fit hook projecting from said lever; b) a drawbar pivotably attached to said lever; c) a chafe attached to said drawbar; d) a catch extending from said support structure to receive saidlever axle; and, e) a first snap fit ledge depending from said supportstructure to engage and hold said first snap fit hook; wherein saidcatch is configured to stand substantially above a nominal height of thesupport structure such that the lever axle is easily received by saidcatch for fastening by the user.
 12. An orthotic device, comprising: alatch mechanism, said latch mechanism, including: a) a lever assembly,comprising: i) a lever; ii) a lever axle depending from said lever at afirst end thereof, for securing the lever to a support structure of theorthotic device; and, iii) a first snap fit hook projecting from saidlever; b) a draw bar pivotably attached to said lever; c) a chafeattached to said draw bar; d) a catch extending from the supportstructure to receive said lever axle; and, e) a first snap fit ledgedepending from the support structure to engage and hold said first snapfit hook; wherein said lever axle is received by said catch forfastening by the user.
 13. The orthotic device of claim 12, wherein saidchafe comprises a D-ring chafe pivotably attached to said draw bar. 14.The orthotic device of claim 12, wherein said lever assembly comprises asecond snap fit hook spaced from said first snap fit hook projectingfrom said lever.
 15. The orthotic device of claim 12, wherein said leverand said snap fit hook are integral.
 16. The orthotic device of claim12, wherein said snap fit hook is engaged or released from said snap fitledge by pulling up on said lever.
 17. The orthotic device of claim 12,wherein said lever comprises a push button that functions to engage orrelease said snap fit hook from said snap fit ledge.
 18. The orthoticdevice of claim 12, wherein said lever comprises a pinch configurationthat functions to engage or release said snap fit hook from said snapfit ledge.